Sports protection device

ABSTRACT

The present invention provides a sports protection device (e.g. a shin pad) for protecting a portion of a wearer&#39;s body (e.g. their shin). The sports protection device comprises a lining layer for facing the wearer&#39;s body (shin) and an opposing composite layer superimposed on said lining layer. The composite layer comprises wood particles within a thermoplastic polymer matrix. The lining and composite layers are shaped to substantially match the contour of the portion of the wearer&#39;s body (shin). A moldable blank for forming a sports protection device is also provided.

The present application claims priority to Great Britain Application No.1610138.8 filed Jun. 10, 2016, the entire contents of which is herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a device for providing protection to anindividual's body whilst participating in sports and/or recreationalactivities. In particular, the present invention relates to acustomizable sports protection device that is moldable to fit a portionof the individual's body to provide shock, impact and frictionprotection during sporting/recreational activities.

BACKGROUND OF THE INVENTION

Many sporting or recreational activities such as soccer, Americanfootball, baseball, hockey, skateboarding, cycling and skiing presentopportunities for an individual to sustain injury through inadvertentcontact either with the ground, sporting equipment and/or otherindividuals. Such injuries typically include bruising/contusion,abrasions, lacerations and bone fractures.

It is known to provide sports protection equipment for use duringsporting/recreational activities to protect vulnerable areas of thebody. For example, it is known to provide protective pads/guards forshins, elbows, wrists and knees. It is obviously a requirement for suchprotective pads that they are both lightweight and highly shockabsorbent. Such protective pads are typically formed of layers offibreglass, foam rubber, polyurethane and nylon. Many individuals findthe known protective pads to be too bulky and thus an impediment totheir sporting performance.

Many known protective pads are provided in standard sizes/shapes devisedto fit an average individual. Straps or integrated socks are provided tomaintain the position of the protective pads. Such standard protectivepads typically provide an imperfect fit for the majority of individualsthus leading to discomfort and compromised protection/sportingperformance.

It is known to provide customizable sports protection pads/guards thatcan be heat moulded to provide an improved fit. For example, it is knownto provide heat moldable mouth guards.

It is also known from US2012/0090068 to provide heat-moldable shinguards that include a moldable thermoplastic layer comprising ethylenevinyl acetate. In order to impart shock resistance and rigidity to theshin guards, the thermoplastic layer is sandwiched between two layers ofcarbon fibre-reinforced plastic, Kevlar™ or fibreglass.

There is a need for protective devices for use in sporting/recreationalactivities that are moldable to fit the individual and that have asimple, lightweight construction whilst retaining high shock absorbency.

SUMMARY OF THE INVENTION

In a first aspect, the present invention provides a sports protectiondevice for protecting a portion of a wearer's body, the sportsprotection device comprising:

-   -   a lining layer for facing the wearer's body; and    -   an opposing composite layer superimposed on said lining layer,        the composite layer comprising wood particles within a        thermoplastic polymer matrix,    -   the lining and composite layers being shaped to substantially        match the contour of the portion of the wearer's body.

In a second aspect, the present invention provides a moldable blank forforming a sports protection device for protecting a portion of awearer's body, the moldable blank comprising:

-   -   a lining layer for facing the wearer's body; and    -   an opposing composite layer superimposed on said lining layer,        the composite layer comprising wood particles within a        thermoplastic polymer matrix,    -   the lining and composite layers being moldable to substantially        match the contour of the portion of the wearer's body.

The present inventors have found that a composite layer comprising athermoplastic polymer and wood particles can be used to provide a sportsprotection device and a moldable blank for forming a sports protectiondevice having a high shock absorbance whilst being lightweight andunbulky. Combined with a liner layer facing the wearer's body, thepresent invention provides a comfortable, customizable, highly effectivesports protection device which can be formed from a moldable blank orcan be provided pre-formed.

Optional features of the invention will now be set out. These areapplicable singly or in any combination with any aspect of theinvention.

The term “sports protection device” is intended to cover a device wornby an individual to maintain their safety and prevent injury arisingfrom sport/recreation.

The device may comprise a primary body portion which is shaped or ismoldable to match the wearer's body portion, the primary body comprisingthe lining layer and composite layer.

The lining layer may be formed of a textile material. The textilematerial may be formed by weaving, knitting, crocheting, knotting,bonding or felting natural fibres such as cotton, hemp, jute, flax orartificial fibres such as polyester, polyamide, polyurethane,polynitrile, ABS, polyolefin (such as polypropylene) fibres.

Performance/technical fabrics including such as COOLMAX®, DRYROAD®,DRI-FIT® or CLIMACOOL® i.e. fabrics that wick moisture away from thewearer's skin are particularly preferred.

The lining layer may be formed of a 3D spacer fabric such as thosemanufactured by Baltex or Apex Mills which provide effective heat andmoisture transfer. A 3D spacer fabric typically comprises athree-dimensional knitted/woven fabric comprising two knitted/wovensubstrates separated by spacer yarns. The spacer yarns allow air andmoisture flow through the fabric between the knitted/woven substrates.The 3D spacer fabric may be formed of polyester, polyamide ofpolypropylene for example.

The lining layer e.g. the 3D spacer may have a thickness of between 1-5mm e.g. around 3 mm.

The lining layer e.g. the 3D spacer fabric may have a weight of between200-500 g/m² e.g. around 350 g/m².

The lining layer may comprise a foam. The foam may be provided insteadof or as well as the textile material described above. The foam may beprovided between the textile material and the composite layer. The foammay be a shock-absorbing foam such as a polyurethane foam e.g. Poron®XRD® foam.

The foam may have a thickness of between 1-20 mm e.g. between 3-8 mmdepending on how much shock absorption is required from the sportsprotection device.

The lining layer e.g. the 3D spacer fabric and/or the foam may comprisean anti-bacterial and/or anti-odour composition. The composition may becoated onto or impregnated into the fabric/foam. For example, the lininglayer may comprise silver ions e.g. such as those provided in Polygiene®or Microban@.

The material used to form the composite layer may be as described inWO2010/103186 herein incorporated by reference.

The thermoplastic polymer is preferably a biodegradable polymer (only)but also non-biodegradable polymers may be utilized.

Examples of polymers include polyolefins, e.g. polyethylene (HD or LD),polypropylene, and polyesters, e.g. poly(ethylene terephthalate) andpoly(butylenes terephthalate), polystyrene homopolymer and copolymersincluding acrylonitrile-butadiene-styrene (ABS), polycarbonates,polyethers, polyetheresters, polyamides e.g. nylon, lactic or butyricacid derivatives, polybenzimidazole (PBI), polyethersulfones (PES),polyvinyl alcohols (PVA), ethyl vinyl acetates (EVA), polyether etherketones (PEEK), polyetherimides (PEI), polyphenylene oxide (PPO),polyphenylene sulphide (PPS), polyvinyl chloride (PVC) and acrylicpolymers. Copolymers, blends and mixtures of polymers may also be used.

The thermoplastic polymer may also be any cross-linked polymersmanufactured prior to processing or in situ during the compoundingprocess for example by means of ionizing radiation or chemicalfree-radical generators. Examples of such polymers are cross-linkedpolyesters, such as polycaprolactone (PCL).

Generally, the weight ratio of biodegradable polymer to anynon-biodegradable polymer is 100:1 to 1:100, preferably 50:50 to 100:1and in particular 75:25 to 100:1.

The thermoplastic polymer may comprise a biodegradable polymer i.e. apolymer which can degrade into natural by-products such as carbondioxide, nitrogen, water, biomass and inorganic salts. By using abiodegradable polymer in combination with the wood particles for thecomposite layer, the sports protection device can be made substantiallybiodegradable offering environmental advantages after disposal.

For example, the thermoplastic polymer may be a thermoplastic polyestere.g. a biodegradable thermoplastic polyester. Suitable examples for thethermoplastic polymer are polylactide, polyglycolide, polycaprolactone(PCL), mixtures/blends thereof and copolymers thereof.

The thermoplastic polymer may comprise a mixture/blend of 5-99 wt %, inparticular 40 to 99 wt %, of a caprolactone homopolymer and 1-95 wt %,in particular 1 to 60 wt %, of another thermoplastic polymer e.g.another biodegradable or non-biodegradable thermoplastic polymer.

Copolymers of caprolactone include copolymers formed with caprolactone,lactic acid and/or glycolic acid monomers. The copolymer may contain atleast 80% by volume of (epsilon) caprolactone monomer, in particular atleast 90% by volume and in particular about 95 to 100% epsiloncaprolactone monomer. The copolymer may contain 5 to 99 wt % andespecially 40 to 99 wt % of repeating units derived from (epsilon)caprolactone monomer with 1 to 95 wt % and especially 1 to 60 wt % ofrepeating units derived from another polymerisable monomer.

The thermoplastic polymer (e.g. the polycaprolactone polymer) may have amolecular weight of between 60,000 g/mol and 500,000 g/mol. For example,the thermoplastic polymer may have a molecular weight between65,000-300,000 g/mol, preferably above 70,000 g/mol such as between75,000 g/mol and 100,000 or 200,000 g/mol. This has been found to beadvantageous both in terms of resultant properties and cost.

The thermoplastic polymer is preferably selected such that it softenswhen it is heated to a temperature of approximately 50 to 70° C., afterwhich the blank can be molded directly on the wearer to create a formthat closely matches the anatomical contours of the portion of thewearer's body.

PCL has a unique melting behavior: The polymer crystals only startmelting when a temperature of approximately 60° C. is reached yet thepolymer crystals start re-forming when temperature is decreased down to37° C. This hysteresis property together with insulating wood particlesin the composite layer of preferred embodiments enables a molding timefor the blank which facilitates use in “field situations” and by userswithout any special competence working with materials.

The molding properties of the present invention can be determined by theaverage molecular weight (Mn) of the polymer, such as epsiloncaprolactone homo- or copolymer. A particularly preferred molecularweight range for the Mn value of PCL is from about 75,000 to about100,000 g/mol, e.g. around 80,000 g/mol.

The number average molar mass (Mn) and the weight average molar mass(Mw) as well as the polydispersity (PDI) were measured by gel permeationchromatography. Samples for GPC measurements were taken directly fromthe polymerization reactor and dissolved in tetrahydrofuran (THF). TheGPC was equipped with a Waters column set styragel HR (1, 2 and 4) and aWaters 2410 Refractive Index Detector. THF was used as eluent with aflow rate of 0.80 ml/min at a column temperature of 35° C. Aconventional polystyrene calibration was used. In determination of thewater content of the monomer at different temperatures a Metroohm 756 KFCoulo meter was used.

The properties of moldability of the present composition can also bedetermined by the viscosity value of the polymer. For an epsiloncaprolactone homopolymer when the inherent viscosity (IV)-value of PCLis less than 1 dl/g the composite is sticky, flows while formed andforms undesired wrinkles while cooling. When PCL having IV-value closerto 2 dl/g is used the composite maintains its geometry during molding onthe wearer and it may be handled without adhesive properties. Thus, IVvalues in excess of 1 dl/g are preferred, values in excess to 1.2 dl/gare preferred and values in excess of 1.3 dl/g are particularlysuitable. Advantageously the values are in the range of about 1.5 to 2.5dl/g, for example 1.6 to 2.1 dl/g. Inherent Viscosity values weredetermined by LAUDA PVS 2.55d rheometer at 25° C. The samples wereprepared by solvating 1 mg of PCL in 1 ml chloroform (CH₃Cl).

The viscosity of the thermoplastic polymer may be relatively high,typically at least 1,800 Pas at 70° C., 1/10 s. The viscosity can be ofthe order of 8,000 to 13.000 Pas at 70° C., 1/10 s (dynamic viscosity,measured from melt phase).

The modulus (Young's modulus) at ambient temperature of thethermoplastic polymer component may be greater than 300 MPa. Bycompounding the thermoplastic polymer with the wood particles, themodulus will increase to about 350 to 2000 MPa for the compositematerial.

The thermoplastic polymer may have a melt flow index of between 0.3 to2.3 g/min (at 80° C.; 2.16 kg).

The thermoplastic polymer may be present in the composite layer in anamount of 5 to 99 wt % (based on the amount of thermoplastic polymer andwood particles). It may be present in an amount between 40 to 99 wt %.

In some preferred embodiments showing particularly good shockabsorption, the thermoplastic polymer is present in an amount of around60 wt % i.e. the weight ratio of wood particles to thermoplastic polymerin the composite layer may be 2:3.

Preferably, the wood particles have a granular or a generally plate-likestructure. Typically, the wood particles are greater in size than apowder.

Particulate or powdered material is characterised typically as materialof a size in which the naked eye can no longer distinguish unique sidesof the particle. Plate-like particles are easily recognizable as onedimension is recognizable by the naked eye as being larger than another.Granular particles, while having substantially equal dimensions, are ofsuch dimension that their unique sides can be determined by the nakedeye and oriented.

More particularly, particulate or powdered materials are of such a smallor fine size that they cannot be easily oriented with respect to theirneighbors. Granular and plate-like particles are of such a size thattheir sides are recognizable and can be orientated.

The wood particles orientate in two dimensions in the thermoplasticpolymer matrix and provide a self-reinforcement effect. As a result, thecomposite layer of the sports protection device provides a gooddimensional stability, good shock absorbance and good punctureresistance.

The wood particles may be present in the composite material forming thecomposite layer in an amount of 1 to 95 wt % (based on the amount ofthermoplastic polymer and wood particles). They may be present in anamount between 1 to 70 wt % or 1 to 60 wt % or 10 to 60 wt % or 20 to 60wt %.

In some preferred embodiments showing particularly good shockabsorption, the wood particles may be present in an amount of around 40wt % i.e. the weight ratio of wood particles to thermoplastic polymer inthe composite material forming the composite layer may be 2:3.

The wood particles may be present in the composite material forming thecomposite layer in an amount of 15 to 50% (based on the volume ofthermoplastic polymer and wood particles). They may be present in anamount between 25 to 50%, by volume.

Before the wood particles are mixed with the thermoplastic polymer theycan be surface treated, e.g. sized, with agents, which modify theirproperties of hydrophobicity/−hydrophobicity and surface tension. Suchagents may introduce functional groups on the surface of the woodparticles to provide for covalent bonding to the matrix. The woodparticles can also be surface treated with polymer e.g. PCL.

The wood particles can be also coated or treated with anti-rot compounde.g. vegetable oil to improve its properties against aging andimpurities.

The wood particles can be dehydrated to make them lighter before mixingwith thermoplastic polymer. The mechanical and chemical properties ofthe wood particles can be improved with heat treatment, which is knownto decrease swelling and shrinkage.

The size and the shape of the wood particles may be regular orirregular. Typically, the particles have an average size (of thesmallest dimension) in excess of 0.02 mm, advantageously in excess of0.1 mm, 0.4 mm or 0.5 mm, for example in excess of 0.6 mm or 1 mm,suitably about 0.6 to 40 mm, in particular about 1.2 to 20 mm,preferably about 1.5 to 10 mm, for example about 1 to 7 mm. For theplate-like wood particles having a length, width and thickness, thesmallest dimension will be the thickness.

The length of the particles (longest dimension of the particles) canvary from a value of greater than 0.6 mm (e.g. greater than 0.75 mm or 1mm or 1.8 mm or 3 mm) to value of up to about 200 mm, for example up toabout 50 mm or 21 mm.

The wood particles can be granular i.e. having a substantially cubicshape, plate-like or a mixture of both. Wood particles considered to begranular have a cubic shape whose ratio of general dimensions are on theorder of thickness:width:length=1:1:1. In practice it is difficult tomeasure each individual particle to determine if it is a perfect cube.Therefore, in practice, particles considered to be granular are thosewhere one dimension is not substantially different than the other two.

Wood particles considered to be plate-like means that they havegenerally a plate-shaped character. The ratio of the thickness of theplate to the smaller of the width or length of the plate's edges isgenerally 1:2 to 1:500 or 1:100 or 1:20 such that the thickness of theplate-like particles is smaller than the width/length.

The plate-like wood particles may have at least two dimensions greaterthan 1 mm and one greater than 0.02 mm (e.g. greater than 0.1 mm), theaverage volume of the wood particles being generally at least 0.02 mm³(e.g. at least 0.1 mm³ or at least 1 mm³). Suitable wood particles havetypical dimensions of 2 mm×2 mm×1 mm, for example.

The specific weight of the wood particles may be between 180-200 kg/m³.

“Derived from platy wood particles” designates that the wood particlesmay have undergone some modification during the processing of thecomposition. For example, if blending of the thermoplastic polymer andwood particles is carried out with a mechanical melt processor, some ofthe original plate-like wood particles may be deformed to an extent.

Typically more than 70% and preferably up to 100% of the wood particlesare greater in size than powder, which particles may be granular orplaty.

The wood species can be freely selected from deciduous and coniferouswood species alike: beech, birch, alder, aspen, poplar, oak, cedar,Eucalyptus, mixed tropical hardwood, pine, spruce and larch tree forexample.

The wood particles can be derived from wood raw-material typically bycutting or chipping of the raw-material. Wood chips of deciduous orconiferous wood species are preferred.

The desired composition of the wood particles can be achieved by siftingwood particles through one or more meshes having one or more varyingqualities. The desired composition can also be accomplished by otherwell-known techniques in the art for sorting and separating particles into desired categories. The desired composition may be the resultantcomposition of one sifting or separating process. The desiredcomposition may also be a mixture of resultant compositions from severalsifting or separation processes.

A particularly interesting raw-material comprises wood particles, chipsor granules, of any of the above mentioned wood species having ascreened size of greater than 0.6 mm up to about 3.0 mm, in particularabout 1 to 2.5 mm on an average.

In addition to wood particles and thermoplastic polymer, the compositelayer can contain reinforcing fibrous material, for example cellulosefibers, such as flax or seed fibers of cotton, wood skin, leaf or barkfibers of jute, hemp, soybean, banana or coconut, stalk fibers (straws)of hey, rice, barley and other crops and plants including plants havinghollow stem which belong to main class of Tracheobionta and e.g. thesubclass of meadow grasses (bamboo, reed, scouring rush, wild angelicaand grass).

In addition, inorganic particulates or powdered materials such as mica,silica, silica gel, calcium carbonate and other calcium salts such astricalcium orthophosphate, carbon, clays and kaolin may be present oradded.

In some embodiments, the composite layer further comprises an elastic orsoft polymer. Such a polymer can be homogenously distributed within thecomposite layer or can be concentrated within regions of the compositelayer.

In some embodiments, the primary body portion is formed of a compositelayer comprising an elastic or soft polymer.

In some embodiments, the sports protection device comprises a hingeportion e.g. a hinge portion connected to the primary body portion. Thehinge portion may be formed of the composite layer as described abovewith or without the lining layer.

The hinge portion may, for example, connect the primary body portion toa secondary body portion, the secondary body portion being provided torest against an opposing side of the wearer's body portion to theprimary body portion to secure the primary body portion in place.

The elastic/soft polymer may be provided in the composite layer at thehinge portion of the sports protection device and/or in the compositelayer forming the primary body portion.

This improves the fit and comfort of the sports protection device.

“Soft” when used in the context of a polymer means that the polymer,either a thermoplastic or thermosetting polymer, has Shore D hardness 27or less at ambient temperature. “Ambient temperature” stands for atemperature of about 10 to 30° C., in particular about 15 to 25° C.

“Region” when used in connection of elasticity or softness of thecomposite layer denotes a portion of the composite layer. The region mayextend only to a limited depth of the composite layer or it may extendthrough the composite layer in at least one dimension. The region maycomprise an elongated, essentially integral area. The region may alsocomprise one or several isolated portions of, for example, materialdifferent from the material surrounding the isolated portion(s).“Region” may also be a portion evenly distributed throughout thecomposite layer. Thus, a soft or elastic polymer can be homogeneouslyblended or mixed with the thermoplastic polymer to extend the region ofelasticity or softness to cover essentially the whole superficial areaof the sports protection device formed by the composite layer. Theregion may be the hinge portion as described above.

A property of “elasticity” or “softness” can be measured by a ringstiffness test, and such a property will be manifested in a greatlyreduced stiffness. Typically the stiffness will be at least 20% lower,preferably at least 30% lower than for a corresponding material, whereinthe same (±10%) volume as taken up by the soft or flexible polymer isformed by the thermoplastic polymer, for example and typically by thethermoplastic polyester or other polymer having melting point orsoftening point below 70° C. and higher or equal to about 55° C.

The elastic/soft polymer is a different polymer than the thermoplasticpolymer. The elastic/soft polymer can be thermoplastic or thermosettingpolymer. The elastic/soft polymer can be used to partly replace thethermoplastic polymer to maintain the total volume of polymer in thecomposite layer at least essentially unaltered.

In a sports protection device/blank having a longitudinal and lateralaxis, the soft (or elastic) polymer rich regions are generallyunidirectional either along the longitudinal or lateral axis. The soft(or elastic) polymer rich regions can also be in form of a grid, mesh orweb.

Typically, the soft/elastic polymer is a polymer having a Shore Dhardness of 27 or less, in particular 25 or less, at ambient temperatureor a thermoplastic elastomer.

Other examples of soft polymers include polymers exhibiting Shore A of 0to 70 and Shore OO of 0 to 90.

The soft/elastic polymer can be formed by a polymer selected from thegroup of thermoplastic polyolefin blends; polyurethanes; co-polyesters;polyamides; unsaturated or saturated rubbers, including natural rubber,silicone, and copolymers of olefins; and natural or synthetic softmaterial, including soft gelatin, hydrogels, hydrocolloids and modifiedcellulose.

The elastic or soft polymer does not need to have melting range in samerange as the thermoplastic polymer. Typically, the soft/elastic polymerhas a melting range outside that of the thermoplastic polymer, inparticular the melting point of the soft/elastic polymer is higher thanthe melting point of the thermoplastic polymer.

In one embodiment, the soft/elastic polymer is miscible withthermoplastic polymer forming a homogenous matrix when processed atelevated temperatures. In another embodiment, the soft/elastic polymeris immiscible with the thermoplastic polymer forming phase-separatedzones or regions within the thermoplastic polymer.

Based on the above, in one embodiment, the composite material comprises:

-   -   10 to 70 parts by weight of thermoplastic polymer e.g. a        biodegradable polyester,    -   25 to 60 parts by weight of wood particles; and    -   5 to 40 parts by weight of a soft or elastic polymer.

Preferably the soft or elastic polymer together with the thermoplasticpolymer (e.g. biodegradable polyester) make up a majority of thecomposite layer (i.e. more than 50% by weight of the total weight of thecomposite layer).

In a particular preferred embodiment, the soft or elastic polymertogether with the thermoplastic polymer (e.g. biodegradable polyester)make up at least 53% and up to 70%, for example 55 to 70%, by weight ofthe total weight of the composite layer. The soft or elastic polymergenerally forms 5 to 50%, in particular 10 to 40%, for example 15 to30%, by weight of the total weight of the thermoplastic polymer (e.g.biodegradable polyester) together with the soft or elastic polymer.

It is possible to incorporate further polymers into the composite layer.In one embodiment, the composition comprises 3 to 30 parts by weight, ofa further polymer comprising a thermoplastic polymer different from thatof the first and the soft/elastic polymer. Such a component can be usedfor achieving improved mechanical properties of the composite layer. Itis also possible to use a fourth polymer to modify the surfaceproperties (for example properties of adhesion) of the composition.

Suitable polymers for the soft/elastic polymer and the further polymerare as described in WO2015/059354.

The composite and lining layers may be affixed directly to one anotherwith no interposing layer.

They may be affixed directly to one another by bonding e.g. bondingusing an adhesive. For example, the lining layer may be pre-impregnatedwith adhesive prior to affixing to the composite layer.

The lining layer may be affixed to the composite layer by heat bondingi.e. by pressing the lining layer onto the composite layer when thecomposite layer is tacky due to heating e.g. during extrusion of thecomposite layer.

The lining layer may be affixed to the composite layer by stitching ormechanical locking.

The sports protection device or blank may further comprise an edginglayer which may extend at least partly (and preferably entirely) aroundthe peripheral edges of at least composite layer and preferably both thelining/composite layers. The edging layer may provide a smooth edge tothe sports protection device or blank to prevent irritation of theportion of the wearer's body against which the sports protection devicefits.

The edging layer may be formed of a textile material or textile stringe.g. a fleece material. The textile material may have a width of between2-6 mm e.g. around 3 mm. It may have a thickness of between 0.5-3 mm,e.g. around 1.5 mm.

The edging layer may be joined around the peripheral edges of thecomposite layer or the lining/composite layers using adhesive e.g.adhesive that is pre-impregnated into the edging layer.

The edging layer may be stitched around the peripheral edges of thecomposite layer or lining/composite layers.

The composite layer may a thickness of about 1 to 50 mm, in particularabout 1.5 to 30 mm, for example 1.5 to 20 mm. The composite layer mayhave a thickness greater than 1.5 mm.

A typical thickness is about 2 to 6 mm, for example between 2 and 4 mm.

With a typical thickness of the composite layer being 2-4 mm and atypical thickness of the lining layer being 1-5 mm, the typicalthickness of the sports protection device is around 3-9 mm making thesports protection device considerably less bulky than the known sportsprotection devices e.g. the known shin pads.

The thickness of the composite layer may vary over the sports protectiondevice/blank. For example, the composite layer may be increase inthickness from its periphery to its centre. For example, the compositelayer may have a thickness of between 4-6 mm e.g. around 4 mm at itscentre decreasing to between 2-4 mm e.g. around 2 mm at its peripheraledges.

The length and the width of the sports protection device and the blankfor forming the sports protection device can vary in the range of about1 to 150 cm (length) and 1 to 50 cm (width). The length and width willvary depending on the body portion requiring protection.

A typical length for a shin pad will be around 10-50 cm, e.g. 15-40 cmin length. A typical width for a shin pad will be around 10 to 20 cm.For example, a shin pad according to the present invention may have alength of around 18 cm and/or a width of around 13 cm. Anotherembodiment of a shin pad (e.g. for use in baseball) may have a length ofaround 32 cm and a width of around 14.5 cm.

The blank may have a substantially planar profile i.e. it may be in theform of a plate or sheet. The plate or sheet may have, for example, arectangular, square, triangular or I-shaped profile. Any apices may berounded.

The blank and/or the sports protection device may have at least aportion having a substantially curved profile. For example, where theblank or sports protection device is for use against the wearer's shins,the blank and/or sports protection device may have a substantiallyU-shaped curved profile. The curvature may be constant or may vary alongits length. For example, the curvature may decrease along its length.

The composite layer may comprise at least one region of non-rigidity toprovide for flexibility and/or aeration in the sports protection device.For example, the composite layer may comprise a region of non-rigidityat the hinge portion.

The or each region of non-rigidity may be formed by perforations in thecomposite layer for example in the form of incisions, in particularunidirectional incisions.

By introducing lengthwise/longitudinal incisions in regions of thecomposite layer, aeration and flexibility can be achieved by merelywidening the composite layer in widthwise direction e.g. during theformation of the sports protection device from the blank.

The incisions are located such that they are kept “closed” in the areasof the sports protection device requiring maximum strength so as not toimpair mechanical strength.

Typically the areas requiring maximal strength are subjected tolongitudinal forces, i.e. forces which act along the length of thedevice. Thus, in one preferred embodiment, the incisions arelongitudinally directed, and they will therefore not be opened by theaction of such longitudinal force. By orientating the incisionslongitudinally, the incisions will remain closed under the influence oflongitudinal forces, and the material will exhibit mechanical strengthand rigidity directly derivable from the structure of the compositelayer.

Wearer comfort is improved by providing some flexibility of thematerial, to allow for some movement, and the composite layer can yieldto forces perpendicular to the general orientation of the incisions byopening the closed incisions.

In the context of the present technology, the pattern and the shape ofthe incisions in the composite material have been studied in particularfor planar composite materials having a thickness in the range of 2 to 4mm.

The incisions studied are formed by straight (linear) incisions or cuts.Preferably there are lines formed with a plurality of incisions. Inparticular there is a plurality of such lines, which preferably areparallel.

In a particular embodiment, the incisions in adjacent lines are off-setsuch that no two adjacent incisions are located along the sametransversal line. Examples of suitable perforations are shown inWO2015/059355.

When subjected to the stretching laterally, the incisions will formapertures. Typically, the perforated composite layer will allowstretching at least 5%, typically up to 75%, in particular about 10 to50%.

During stretching, the non-rigid region of the composite layer will havepore area which is 2× to 100×, typically 2.5× to 15× greater that thanpore area of the corresponding non-stretched, non-incised compositelayer. The pore area can be about 2.5 to 30% of the total area of thenon-rigid region, for example about 3 to 20%, for example about 5 to15%.

It has been found that incisions having a length of generally more 20 mmmay cause tearing of the material when exposed to strong twisting andstrain. On the other hand, incisions which are less than 5 mm in lengthdo not sufficiently open during molding the material onto the human limbto allow for proper aerating.

Further, the space between each incision in longitudinal direction mustexceed 5 mm to avoid tearing of the material and be less than 20 mm toachieve sufficient level of aerating.

The space between each incision line transversally to the linearincision must exceed 10 mm to avoid tearing and be less than 25 mm toachieve sufficient level of aerating. The incisions may be manufacturedinto the composite profile with an incision device, examples of suitableequipment include a rolling cylinder or a press equipped with blades,water jet, and laser cutting.

Typically, the incisions have a width of 0.1 to 1 mm, preferably 0.3 to0.8 mm, and a length of 4 to 20 mm.

The incisions can be made with a blade, the surface area of whichincisions being on the blade ingoing side about 1 to 10 mm², preferably2.5 to 8 mm². The number of incisions per 10 cm² may be generally 20 to100, preferably 30 to 70.

The particular advantage of incorporating incisions into the compositelayer is that upon forming the sports protection device e.g. by moldingthe blank, the incisions will yield openings which give the compositelayer properties of breathability and flexibility in the non-rigidregion(s) e.g. at the hinge portion.

The shape of the openings or apertures formed by stretching of theincisions can be, for example, round, rectangular, square, diamond,hexagonal, oval, slot or ornamental perforation. The surface area of onehole should be generally about 3 to 30 mm² and the number of the holesis kept between 20 holes/10 cm² and 100 holes/10 cm². The total openarea is less than 10 percentage of the whole surface area.

The composite layer of the primary body portion of the sports protectiondevice may be solid (and may be substantially rigid) i.e. may contain noapertures/perforations/incisions. Where the sports protection device isa shin pad or wrist guard, for example, the composite layer of theprimary body portion (for protecting the wearer's shin or wrist) ispreferably solid. In wrist guard embodiments, the composite layer of theprimary body portion may comprise the soft/elastic polymer as describedabove.

For larger sport protection devices such as torso or head guards,apertures/perforations/incisions may be provided in the primary bodyportion to provide aeration.

In a third aspect, the present invention provides a method ofmanufacturing a sports protection device for protecting a portion of awearer's body, the method comprising:

-   -   providing a lining layer for facing the wearer's body;    -   superimposing a composite layer on said lining layer, the        composite layer comprising wood particles within a thermoplastic        polymer matrix,    -   shaping said layers to substantially match the contour of the        portion of the wearer's body.

In a fourth aspect, the present invention provides a method ofmanufacturing a moldable blank for forming a sports protection devicefor protecting a portion of a wearer's body, the method comprising:

-   -   providing a lining layer for facing the wearer's body;    -   superimposing a composite layer on said lining layer, the        composite layer comprising wood particles within a thermoplastic        polymer matrix.

The lining layer and composite layer may be as described above for thefirst and second aspects.

The composite layer can be manufactured by mixing the thermoplasticpolymer (as described above) with the wood particles (as describedabove). The thermoplastic polymer may be provided in the form ofpellets.

The method may comprise the steps of mixing together 10 to 100 parts,preferably 50 to 100 parts by weight of the thermoplastic polymer and 1to 100 parts, preferably 10 to 50 parts, by weight of wood particles. Insome embodiments, the method comprises mixing together the thermoplasticpolymer and wood particles in a ratio of 3:2 (by weight).

The thermoplastic polymer (e.g. pellets) and wood particles may be mixedusing melt mixing/processing e.g. in a heatable vessel having amechanical stirrer to produce a compounded melt mixture. The meltmixture can then be extruded.

The mixing can be melt mixing carried out at a temperature sufficientfor melting the thermoplastic polymer, e.g. at about 50 to 150° C.Alternatively, the temperature can be in the range of about 80 to 190°C., preferably about 100 to 150° C.

The uniformity of the composite layer can be increased by using anextruder, kneader or any device suitable for mixing thermoplasticpolymers.

By using an extruder mixing apparatus, two hoppers, each containing oneof the two components of the composite layer, can deposit the desiredamount of each component (thermoplastic polymer and wood particles) into the mixing chamber of the apparatus. Alternatively, the wood chipsand polymer granules may mixed to form a uniform blend before pouringinto the feed hopper of an extruder. Then, by way of thestirrer/agitator in the mixing apparatus, there is formed a homogeneousmixture of the thermoplastic and wood particles prior to the formationof the composite layer.

One advantage to the material being formed by such a homogeneous mixtureof the components is that the forces necessary to form a substantiallyhomogeneous material are reduced. Therefore, little or no compressionforce is necessary to facilitate mixing of the components in a materialformation step. The importance of this factor is that, by way of thehomogeneous mixture, larger particles of each component can be usedwhich would otherwise have been destroyed when subjected to highcompression forces.

The composite layer can be formed, for example, by extruding the mixtureof thermoplastic polymer and wood particles using an appropriate nozzlee.g. to form a sheet or plate. The extruder may be a single screwextruder. The nozzle is selected to give the desired thickness andprofile of the composite layer including a composite layer of varyingthickness as described above.

In the compounding process the profile of the extruder screw ispreferably such that its dimensions will allow relatively large woodchips to move along the screw without crushing them. Thus, the channelwidth and flight depth are selected so that the formation of excessivelocal pressure increases, potentially causing crushing of the woodparticles, are avoided. The temperature of the cylinder and the screwrotation speed are also selected such as to avoid decomposition of woodchip structure by excessively high pressure during extrusion. Forexample a suitable barrel temperature can be in the range of about 110to 150° C. from hopper to die, while the screw rotation speed may bebetween 25-50 rpm. These are, naturally, only indicative data and theexact settings will depend on the actual apparatus used.

The molten thermoplastic polymer containing the wood particles can besubjected to tensile forces to achieve a desired orientation of thethermoplastic polymer and, in particular, the wood particles.

The desired 2D profile for the composite layer for the sports protectiondevice/blank can be obtained from the extruded sheet or plate with e.g.laser cutting, water jet cutting, eccentric pressing or with any toolcapable for producing regular shape profiles.

The composite layer with the appropriate 2D profile can also be formedby compression molding, injection molding, die-casting, pressuredie-casting or manual shaping.

A particular advantage of the present invention is that the compositelayer and lining layer forming the blank can be cut to its 2D profileusing scissors i.e. without any specialist cutting tools.

Other features of the steps of manufacturing the composite layer may beas described in WO2010/103188 incorporated herein by reference.

At least one region of non-rigidity can be provided e.g. at a hingeportion of the sports protection device by forming incisions or by usingpolymer mixtures with more elasticity as described above. The incisionscan be formed into the composite layer during or subsequent to extrusionof the composite layer e.g. using a rolling cylinder or a press equippedwith blades, water jet or laser cutting. In these embodiments, theprimary body portion of the sports protection device (i.e. the portionwhich rests against the wearer's body portion) may be substantiallyrigid (i.e. not containing soft/elastic polymers) and may be withoutincisions/soft/elastic polymer whilst incisions or soft/elastic polymeris provided only at the hinge portion.

The composite and lining layers (as described above) be affixed directlyto one another with no interposing layer. They may be affixed before orafter the formation of the sports protection device/blank into thedesired 2D profile.

They may be affixed directly to one another by bonding e.g. bondingusing an adhesive. For example, the lining layer may be pre-impregnatedwith adhesive prior to affixing to the composite layer.

The lining layer may be affixed to the composite layer by heat bondingi.e. by pressing the lining layer onto the composite layer when thecomposite layer is tacky due to heating e.g. during extrusion of thecomposite layer.

The lining layer may be affixed to the composite layer by stitching ormechanical locking.

The method may further comprise affixing an edging layer which mayextend at least partly (and preferably entirely) around the peripheraledges of the layers. The edging layer may provide a smooth edge to thesports protection device or blank to prevent irritation of the portionof the wearer's body against which the sports protection device fits.The edging layer may be affixed using adhesive and/or stitching, forexample.

To form the 3D profile of the sports protection device of the firstaspect and/or to mold the blank according to the second aspect, thecomposite/lining layers are heated to the desired operating temperatureby a heating device.

Once the composite/lining layers are heated to the desired temperature,then the layers can be formed into the desired profile. For example, theblank can be placed on the wearer in the desired location to form thesports protection device. The advantage of the present material is thatit can be handled by hand without any protective requirement such asgloves.

Equally important is that the material can be formed directly againstthe wearer's skin. The wood particles form insulating regions within thethermoplastic polymer (which is moldable at low temperature) such thatthe composite layer is comfortable to touch with bare hands.

With the composite material still pliable and moldable, it can becontoured to fit the wearer's body part nearly or exactly. Additionally,if the initial placement is not desirable, the blank can be moved whilestill moldable to a more desirable location. If the composite layer haslost its desired moldability, then it can be reheated and likewise movedto the new location. A blank formed of PCL and wood particles typicallyremains moldable for up to 5 minutes. One of the particular advantagesof the present material is that it can be heated and cooled many timeswithout degrading its mechanical properties.

When the blank is located properly and molded to the desired form, thenit can be allowed to cool to a temperature where it can be removed butmaintain its shape. The cooling may be accomplished by allowing theambient conditions to reduce the temperature of the material or thecooling may be aided by spraying the material with water or anotherchemical to speed up the cooling. Additionally, solid cooling means canbe used to cool the material such as a cold pack or ice place directlyagainst the composite material.

The sports protection device may be contoured or the blank may bemoldable to fit against the wearer's limb.

For example, the sports protection device may comprise or the blank maybe moldable to form a shin pad, an elbow pad, a knee pad, an ankleguard, a shoulder pad/guard or a wrist guard. In these embodiments, thesports protection device may be contoured/dimensioned to only partlyencircle the wearer's limb so that weight of the device is minimised andease of fitting is optimised.

For example, a shin pad may have a substantially U-shaped profile. Ablank for a shin pad may have a substantially rectangular shape that ismoldable into a U-shaped profile. The curvature of the U-shaped profilemay be constant or may vary along its length. For example, the curvaturemay decrease along its length.

The blank may have a cut-out portion at one end—this cut-out portion mayprovide for flexing of the wearer's ankle once the blank has beenmoulded into the shin pad.

A typical length for a shin pad will be around 10-50 cm, e.g. 15-40 cmin length. A typical width for a shin pad will be around 10 to 20 cm.For example, a shin pad according to the present invention may have alength of around 18 cm and/or a width of around 13 cm. Anotherembodiment of a shin pad (e.g. for use in baseball) may have a length ofaround 32 cm and a width of around 14.5 cm.

In another example, a blank for an elbow guard may have a planarsubstantially triangular shape optionally with rounded apices. Thetriangular shape may be an isosceles triangle with a width of around190-250 mm (e.g. 200 or 230 mm) and a height of around 110-160 mm (e.g.125 mm or 145 mm).

In another example, a blank for a wrist guard (e.g. for use in baseball)may have a planar substantially square/rectangular shape with optionallyrounded apices. One side of the square shape may be convex whilst theopposing side may be concave. The sides may be around 75-150 mm, e.g.70-90 mm. The convex/concave sides may be shorter than the adjoiningsides. For example, in one embodiment, the adjoining sides may be around85 mm whilst the concave/convex sides may be around 77.5 mm. The blankis moldable into a U-shaped profile the fit the wearer's wrist.

In another embodiment of a wrist guard (e.g. for use in fightingsports), the wrist guard has a substantially planar elongated portionfor contacting the upper surface of the wearer's wrist with curledcentral edges for partially encircling the wearer's wrist, the curledcentral edges tapering to the planar portion at the opposing lateralends of the planar portion. The length of the planar elongated portionmay be around 100-250 mm with a width of around 150-190 mm. The heightof the curled edges may be around 125-160 mm. In these embodiments, thecomposite layer may comprise a soft/elastic polymer as described above.Such a wrist guard can be worn under a boxing glove and secured in placeusing bandages (which are currently often used under boxing gloves). Thewrist guard contours against the wrist to provide support. Embodimentscontaining the soft/elastic polymer as described above are able to flexand allow comfortable movement of the wearer's wrist e.g. upon impact ofthe boxing glove.

The blank for forming this wrist guard may have a planar substantiallyrectangular/square shape with optionally rounded apices. The sides maybe around 130-180 mm, e.g. around 150 mm. A cut-out may be provided atone corner of the blank for accommodating the wearer's thumb duringmolding.

In other embodiments, the sports protection device may be contoured orthe blank may be moldable to fit against the wearer's face/head (e.g.nose/forehead), groin, chest or back.

A blank for a nose guard may have a planar substantially I-shapedprofile with two opposing horizontal portions (for molding over the rootand tip of the nose) separated by a vertical web (for molding over thebridge of the nose). The upper horizontal portion (for molding over theroot of the nose) may have a greater extension (from the web) than thelower horizontal portion (for moulding over the tip of the nose). Forexample, the upper horizontal portion may have a total extension (width)of around 120 mm. The height of the blank (from the upper edge of theupper horizontal portion to the lower edge of the lower horizontalportion) may be around 90 mm.

In some embodiments, the sports protection device may comprise at leastone fastener for affixing the sports protection device to the portion ofthe wearer's body. The at least one fastener may comprise a strap e.g. astrap that is securable to a further strap or to the sports protectiondevice using a hook/loop connection (e.g. Velcro™).

The fastener may be provided on the primary body portion and/or thesecondary body portion.

In other embodiments, the sports protection device may not include anyfastener. For example, the composite layer has been found to have asufficiently rough surface (owing to the presence of wood particles)that it can frictionally engage with the wearer's clothing e.g. socks,to maintain its position against the portion of the wearer's body e.g.shin or in the case of the wrist guard described above, it canfrictionally engage with bandages underneath a fighting/boxing glove tosecure it against the wearer's wrist. This provides for secure affixingof the sports protection device without the need for fasteners (whichcomplicate the manufacturing process).

In a fifth aspect, the present invention provides a shin pad forprotecting a wearer's shin, the shin pad comprising:

-   -   a lining layer for facing the wearer's shin; and    -   an opposing composite layer superimposed on said lining layer,        the composite layer comprising wood particles within a        thermoplastic polymer matrix,    -   the lining and composite layers being shaped to substantially        match the contour of the wearer's shin.

In a sixth aspect, the present invention provides a moldable blank forforming a shin pad for protecting a wearer's shin, the moldable blankcomprising:

-   -   a lining layer for facing the wearer's shin; and    -   an opposing composite layer superimposed on said lining layer,        the composite layer comprising wood particles within a        thermoplastic polymer matrix,    -   the lining and composite layers being moldable to substantially        match the contour of the wearer's shin.

The lining layer and composite layers may be as described above and maybe joined as described above. The shin pad/blank may further comprisethe edging layer as described above.

The shin pad/blank may be manufactured as described for the third andfourth aspects respectively.

With a typical thickness of the composite layer being 2-4 mm and atypical thickness of the lining layer being 1-5 mm, the typicalthickness of the shin pad is around 3-9 mm making it considerably lessbulky than the known shin pads.

A typical length for a shin pad will be around 10-50 cm, e.g. 15-40 cmin length. A typical width for a shin pad will be around 10 to 20 cm.For example, a shin pad according to the present invention may have alength of around 18 cm and/or a width of around 13 cm. Anotherembodiment of a shin pad (e.g. for use in baseball) may have a length ofaround 32 cm and a width of around 14.5 cm.

The blank and/or the shin pad may have at least a portion having asubstantially curved profile. For example, the blank and/or shin pad mayhave a substantially U-shaped curved profile. The curvature may beconstant or may vary along its length. For example, the curvature maydecrease along its length (e.g. towards a lower end).

Alternatively, the blank may have a substantially planar e.g. planarrectangular shape for molding into the curved profile.

The blank and/or the shin pad may have a cut-out portion at the lowerend for molding around and allowing flexing of the wearer's ankle.

The blank/shin pad is preferably dimensioned such that it only partiallyencircles the wearer's leg i.e. it encircles the wearers shin but nottheir calf.

The shin guard may comprise at least one fastener for affixing the shinguard to the wearer's shin. The at least one fastener may comprise astrap e.g. a strap that is securable to a further strap or to the sportsprotection device using a hook/loop connection (e.g. Velcro™). Thefastener may be provided on the primary body portion and/or thesecondary body portion.

In other embodiments, the shin pad may not include any fastener. Forexample, the composite layer has been found to have a sufficiently roughsurface (owing to the presence of wood particles) that it canfrictionally engage with the wearer's clothing e.g. socks, to maintainits position against the wearer's shin. This provides for secureaffixing of the shin pad without the need for fasteners (whichcomplicate the manufacturing process).

The shin pad may comprise an ankle guard extending from the compositelayer. The ankle guard may be formed of padded, elastic material and maybe detachable from the composite layer.

In some embodiments, the shin guard/blank comprises a primary bodyportion formed of the lining layer and the composite layer (as describedabove) which matches or is moldable to match the wearer's shin, and atleast one hinge portion for securing the primary body portion to asecondary body portion.

The secondary body portion is for maintaining the primary body portionin position against the wearer's shin by being held against the wearer'scalf with the at least one hinge portion connecting the primary andsecondary body portions.

The at least one hinge portion may comprise a composite layer asdescribed with the soft/elastic polymer blended/mixed with thethermoplastic polymer.

The composite layer of the primary body portion may be substantiallysolid i.e. without apertures/perforations/incisions extending over themajority of its surface i.e. over the surface which, in use, overlaysthe portion of the wearer's body. In preferred embodiments, the majorportion of the composite layer of the primary body portion is solid i.e.without apertures/perforations/incisions. A minor portion e.g. theperiphery of the composite layer of the primary body portion maycomprise one or more apertures purely for the purpose of affixing orsecuring any fastener provided. Where no fastener is provided, noapertures are required.

The hinge portion may comprise incisions as described above.

In a seventh aspect, the present invention provides kit comprising ashin pad according to the fifth aspect and a sock, the sock having apouch into which the shin pad can be inserted. In these embodiments, nofasteners are needed to secure the shin pad.

The pouch may be defined by two opposing layers of material, the twolayers defining a cavity into which the shin pad can be inserted.

In an eighth aspect, the present invention provides a wrist guard forprotecting a wearer's wrist, the wrist guard comprising:

-   -   a lining layer for facing the wearer's wrist; and    -   an opposing composite layer superimposed on said lining layer,        the composite layer comprising wood particles within a        thermoplastic polymer matrix,    -   the lining and composite layers being shaped to substantially        match the contour of the wearer's wrist.

In a ninth aspect, the present invention provides a moldable blank forforming a wrist guard for protecting a wearer's wrist, the moldableblank comprising:

-   -   a lining layer for facing the wearer's wrist; and    -   an opposing composite layer superimposed on said lining layer,        the composite layer comprising wood particles within a        thermoplastic polymer matrix,    -   the lining and composite layers being moldable to substantially        match the contour of the wearer's wrist.

The lining layer and composite layers may be as described above and maybe joined as described above. The wrist guard/blank may further comprisethe edging layer as described above.

The wrist guard/blank may be manufactured as described for the third andfourth aspects respectively.

With a typical thickness of the composite layer being 2-4 mm and atypical thickness of the lining layer being 1-5 mm, the typicalthickness of the wrist guard is around 3-9 mm allowing it to be wornunder a fighting e.g. boxing glove.

A wrist guard according to embodiments of the present invention may havea length of around 15 cm and/or a width of around 15 cm.

The blank and/or the wrist guard may have at least a portion having asubstantially curved profile. For example, the blank and/or wrist guardmay have a substantially U-shaped curved profile. The curvature may beconstant or may vary along its length. For example, the curvature maydecrease along its length (e.g. towards a lower end).

In some embodiments, a blank for a wrist guard (e.g. for use inbaseball) may have a planar substantially square shape with optionallyrounded apices. One side of the square shape may be convex whilst theopposing side may be concave. The sides may be around 75-150 mm, e.g.70-90 mm. The convex/concave sides may be shorter than the adjoiningsides.

For example, in one embodiment, the adjoining sides may be around 85 mmwhilst the concave/convex sides may be around 77.5 mm. The blank ismoldable into a U-shaped profile the fit the wearer's wrist.

In another embodiment of a wrist guard (e.g. for use in fightingsports), the wrist guard may have a substantially planar elongatedportion for contacting the upper surface of the wearer's wrist withcurled central edges for partially encircling the wearer's wrist, thecurled central edges tapering to the planar portion at the opposinglateral ends of the planar portion. The length of the planar elongatedportion may be around 100-250 mm with a width of around 150-190 mm. Theheight of the curled edges may be around 125-160 mm. In theseembodiments, the composite layer may comprise a soft/elastic polymer asdescribed above. Such a wrist guard can be worn under a boxing glove andsecured in place using bandages (which are currently often used underboxing gloves). The wrist guard contours against the wrist to providesupport. Embodiments containing the soft/elastic polymer as describedabove are able to flex and allow comfortable movement of the wearer'swrist e.g. upon impact of the boxing glove.

The blank for forming this wrist guard may have a planar substantiallyrectangular/square shape with optionally rounded apices. The sides maybe around 130-180 mm, e.g. around 150 mm. A cut-out may be provided atone corner of the blank for accommodating the wearer's thumb duringmolding.

The blank/wrist guard is preferably dimensioned such that it onlypartially encircles the wearer's wrist.

The wrist guard may comprise at least one fastener for affixing thewrist guard to the wearer's wrist. The at least one fastener maycomprise a strap e.g. a strap that is securable to a further strap or towrist guard using a hook/loop connection (e.g. Velcrom™). The fastenermay be provided on the primary body portion and/or the secondary bodyportion.

In other embodiments, the wrist guard may not include any fastener. Forexample, the composite layer has been found to have a sufficiently roughsurface (owing to the presence of wood particles) that it canfrictionally engage with bandages worn around the wearer's wrist e.g.under boxing gloves.

This provides for secure affixing of the wrist guard without the needfor fasteners (which complicate the manufacturing process).

In some embodiments, the wrist guard/blank comprises a primary bodyportion formed of the lining layer and the composite layer (as describedabove) which matches or is moldable to match the wearer's wrist and theprimary body portion comprise a composite layer as described with thesoft/elastic polymer blended/mixed with the thermoplastic polymer. Thisallows comfortable flexing of the wearer's wrist e.g. during impactduring boxing.

The composite layer of the primary body portion may be substantiallysolid i.e. without apertures or perforations or incisions extending overthe majority of its surface i.e. over the surface which, in use,overlays the portion of the wearer's body. In preferred embodiments, themajor portion of the composite layer of the primary body portion issolid i.e. without apertures/perforations/incisions. A minor portione.g. the periphery of the composite layer of the primary body portionmay comprise one or more apertures purely for the purpose of affixing orsecuring any fastener provided. Where no fastener is provided, noapertures are required.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a first embodiment of a moldable blank wrist guardaccording to an aspect of the present invention;

FIGS. 2a and 2b show a wrist guard formed of the moldable blank shown inFIG. 1;

FIG. 3 shows a second embodiment of a moldable blank according to anaspect of the present invention;

FIG. 4 shows a wrist guard formed of the moldable blank shown in FIG. 3:

FIG. 5 shows the wrist guard of FIG. 4 in position on a wearer's wrist;

FIG. 6 shows the wrist guard of FIG. 4 with a fastening strap; and

FIG. 7 shows the wrist guard of FIG. 6 in position on a wearer's wrist.

DETAILED DESCRIPTION AND FURTHER OPTIONAL FEATURES OF THE INVENTION

FIG. 1 shows a moldable blank 1 comprising a primary body portion 2, asecondary body portion 3 and two hinge portions 4 a, 4 b.

The primary body portion 2 and secondary body portion 3 are each formedof a lining layer 5 comprising a 3D spacer fabric having a thickness ofbetween 1 to 5 mm and a composite layer 6 comprising a polycaprolactonematrix (with a mw of 80,000 g/mol) with plate-like wood particles havingan average size of 2×2×1 mm, the ratio of the polymer matrix to the woodparticles being 3:2. As FIG. 1 shows a top view of the blank, thecomposite layer 6 can be clearly seen but the lining layer 5 is onlyvisible at the very edges as it is overlaid by the composite layer 6.

The composite layer 6 of the primary body portion 2 (and the secondarybody portion 3) is solid i.e. the composite layer 6 of the primary bodyportion 2 which, in use, overlays the portion of the wearer's wristrequiring protection contains no apertures/perforations.

The hinge portions 4 a, 4 b connect the primary body portion 2 and thesecondary body portion 3 and are also formed of a composite layer 6 andlining layer 5. The thermoplastic polymer matrix in the composite layer6 of the hinge portion 4 a, 4 b additionally comprises a soft/elasticpolymer to provide flexibility in the hinge portions.

The primary body portion 2 and secondary body portion 3 each include twolarge hook and loop connection elements 8 a, 8 b and two smaller hookand loop connection elements 8 d, 8 c.

The primary and secondary body portions of the moldable blank 1 areheated and moulded to form a wrist guard 9 to fit a wearer's wrist asshown in FIGS. 2a and 2 b.

The primary body portion 2 and secondary body portion 3 are affixedeither side of the wearer's wrist using a first strap 7 a which isaffixed between the large hook and loop connection elements 8 a and 8 b(passing around the inside of the wearer's wrist), and a second strap 7b which is affixed between the smaller hook and loop connection elements8 c and 8 d (passing between the wearer's thumb and fingers).

The wrist guard 9 has a substantially planar elongated primary bodyportion 2 for contacting the upper surface of the wearer's wrist. Thesecondary body portion 3 has curled edges 11 for partially encirclingthe underside of the wearer's wrist. Together, the primary body portion2 and secondary body portion 3 provide protection against wrist injury.

FIG. 3 shows another moldable blank 1′ for forming a wrist guard. Theblank is formed of a composite layer 6′ comprising a polycaprolactonematrix (with a mw of 80,000 g/mol). The polymer matrix additionallycomprises a soft/elastic polymer. The polymer matrix contains plate-likewood particles having an average size of 2×2×1 mm, the ratio of thepolymer matrix to the wood particles being 3:2. The thickness of thecomposite layer 6′ is 2 mm. The composite layer 6′ is solid i.e.contains no perforations or incisions.

The blank has a substantially square profile with rounded apices 10 andedges 11′ of approximately 15 cm length. A cut-out 12 is provided at onecorner (which provides space for the wear's thumb).

The composite layer 6′ is secured to a lining layer (not shown in FIGS.3-5) formed of 3D spacer fabric having a thickness of 1-5 mm.

The moldable blank 1′ may be heated and moulded to match the contour ofthe wearer's wrist to form a wrist guard 9′ as shown in FIGS. 4 and 5.This wrist guard 9′ has a substantially planar elongated primary bodyportion 2′ for contacting the upper surface of the wearer's wrist withcurled central edges 11′ for partially encircling the wearer's wrist,the curled central edges 11′ tapering to the primary body portion 2′ atthe opposing lateral ends of the planar primary body portion 2′. Thelength of the planar elongated primary body portion 2′ may be around 150mm with a width of around 10 mm. The height of the curled edges 11′ maybe around 125-160 mm.

Such a wrist guard 9′ can be worn under a boxing glove and secured inplace using bandages (which are currently often used under boxinggloves). The wrist guard 9′ contours against the wrist to providesupport. The soft/elastic polymer in the composite layer allows thewrist guard to flex and allow comfortable movement of the wearer's wriste.g. upon impact of the boxing glove.

FIGS. 6 and 7 show another embodiment of the wrist guard 9″ similar tothat shown in FIGS. 4 and 5 but where a fastening strap 7′ is providedto secure the wrist guard in place. The fastening strap 7′ comprises ahook and loop fastening element such as Velcro™ which secures the strap7′ to itself to hold the wrist guard 9″ in place. The lining layer 5′ isvisible in FIGS. 6 and 7.

Example—Comparative Shock Absorption Test

Test specimens with dimensions of 50 mm×50 mm were cut from the plasticshell of three commercially available shin guards (after separation ofthe shell from the associated foam/textile layers). Additionally threesets of 50 mm×50 mm test samples were cut from a composite layer havinga thickness of 4 mm and a composite layer having a thickness of 2 mm.The composite layer was formed from a 3:2 ratio of PCL and woodparticles. The wood particles were aspen wood particles having anaverage size of 2×2×1 mm. The PCL had a Mn of 80,000 g/mol.

The composite layers were heated and formed to have identical shape asthe comparative shin guard specimens to exclude the effect of shape inresults. The thickness of each test specimen was measured with caliperat both ends of the specimen, to calculate average thickness.

A blunt impact test set up was used to assess the impact absorbingproperties of the test specimens and composite layer samples by droppinga 2.5 kg mass from 47 mm distance, positioned vertically over the top ofthe test specimen/samples. The amount of force that was transmittedthrough the guard onto the flat anvil was measured (via instrumentKistler9065 for measuring impact force) and recorded. The lower thetransmitted force the better the shock absorption property of thesample.

Three measurements were performed for each test specimen/sample.

Transmitted force averages and standard deviations were calculated foreach test specimen/sample. An independent paired two-tailed t-test wasused to test the hypothesis that there is a difference between twomaterials. A value of P<0.05 indicates a statistically significantdifference between the two materials.

The transmitted force values (averages from three measurements) areshown in Table 1.

TABLE 1 Transmitted Force k (N) Material Thickness (mm) (average-stdev)Test specimen 1 3.2 4.57 +/− 0.13 Composite layer 4 mm 4.2 2.90 +/− 0.09Composite layer 2 mm 2.2 3.98 +/− 0.16 Test specimen 2 2.9 5.97 +/− 0.27Composite layer 4 mm 4.3 2.97 +/− 0.19 Composite layer mm 2.2 4.24 +/−0.11 Test specimen 3 3.0 5.02 +/− 0.51 Composite layer 4 mm 4.2 3.73 +/−0.19 Composite layer 2 mm 2.1 4.26 +/− 0.05

The 4 mm composite layer clearly provides the best shock absorptionamongst the specimens/samples tested. The 2 mm composite later has onlyapproximately ⅔ of the thickness of the test specimens, however theshock absorption property was either higher (Test specimen 1; P=0.009and Test specimen 2; P=0.048) or around the same level (Test specimen 3;P=0.171), in this test.

The composite layer can be used to provide a sports protection devicehaving high shock absorbance but with a narrow profile, reducedbulkiness and lower weight compared to known products. The lining layerprovides comfort for the wearer.

The 3D moldability of the composite layer in the blanks according to thesecond and sixth aspects further improves comfort and shock absorbency.

While the invention has been described in conjunction with the exemplaryembodiments described above, many equivalent modifications andvariations will be apparent to those skilled in the art when given thisdisclosure. Accordingly, the exemplary embodiments of the invention setforth above are considered to be illustrative and not limiting. Variouschanges to the described embodiments may be made without departing fromthe spirit and scope of the invention.

All references referred to above are hereby incorporated by reference.

1. A sports protection device for protecting a portion of a wearer'sbody, the sports protection device comprising: a lining layer for facingthe wearer's body; and an opposing composite layer superimposed on saidlining layer, the composite layer comprising wood particles within athermoplastic polymer matrix, the lining and composite layers beingshaped to substantially match the contour of the portion of the wearer'sbody.
 2. A device according to claim 1 wherein the thermoplastic polymeris polycaprolactone and wherein the wood particles are plate-like andthe ratio of the thickness of the plate to the smaller of the width orlength of the plate is generally 1:2 to 1:500.
 3. A device according toclaim 1 wherein the lining layer comprises a 3D spacer fabric having athickness of between 1-5 mm.
 4. A device according to claim 1 whereinthe sports protection device comprises a primary body portion shaped tosubstantially match the contour of the portion of the wearer's body andwherein a major portion of the composite layer of the primary bodyportion is solid.
 5. A device according to claim 3 wherein the primarybody portion has a central portion that is thicker than a peripheralportion.
 6. A device according to claim 5 wherein the composite layerhas a thickness of between 2-6 mm.
 7. A device according claim 1comprising a hinge portion and wherein said composite layer at the hingeportion further comprises a soft or elastic polymer or wherein saidcomposite layer at the hinge portion further comprises incisions in theregion of increased flexibility.
 8. A device according to claim 1wherein the sports protection device is a shin pad for protecting awearer's shin with the lining layer for facing the wearer's shin, andthe lining and composite layers being shaped to substantially match thecontour of the wearer's shin.
 9. A device according to claim 4 whereinthe composite layer forming the primary body portion further comprises asoft or elastic polymer.
 10. A device according to claim 1 wherein thedevice is a wrist guard for protecting a wearer's wrist with the lininglayer for facing the wearer's wrist, and the lining and composite layersbeing shaped to substantially match the contour of the wearer's wrist,wherein the composite layer further comprises a soft or elastic polymer.11. A kit comprising a device according to claim 7 and a sock having apouch for insertion of said device.
 12. A moldable blank for forming asports protection device for protecting a portion of a wearer's body,the moldable blank comprising: a lining layer for facing the wearer'sbody; and an opposing composite layer superimposed on said lining layer,the composite layer comprising wood particles within a thermoplasticpolymer matrix, the lining and composite layers being moldable tosubstantially match the contour of the portion of the wearer's body. 13.A blank according to claim 12 wherein the thermoplastic polymer ispolycaprolactone and wherein the wood particles are plate-like and theratio of the thickness of the plate to the smaller of the width orlength of the plate is generally 1:2 to 1:500.
 14. A blank according toclaim 12 wherein the lining layer comprises a 3D spacer fabric having athickness of between 1-5 mm.
 15. A blank according to claim 12 whereinthe sports protection device comprises a primary body portion moldableto substantially match the contour of the portion of the wearer's bodyand wherein a major portion of the composite layer of the primary bodyportion is solid.
 16. A blank according to claim 15 wherein the primarybody portion has a central portion that is thicker than a peripheralportion.
 17. A blank according to claim 16 wherein the composite layerhas a thickness of between 2-6 mm.
 18. A blank according claim 12comprising a hinge portion and wherein said composite layer at the hingeportion further comprises a soft or elastic polymer or wherein saidcomposite layer at the hinge portion further comprises incisions in theregion of increased flexibility.
 19. A blank according to claim 18further comprising an edging layer extending at least partly around theperipheral edges of the composite layer.
 20. A moldable blank accordingto claim 19 wherein the moldable blank is for forming a shin pad forprotecting a wearer's shin, the lining layer for facing the wearer'sshin, and the lining and composite layers being moldable tosubstantially match the contour of the wearer's shin.